Ventilation exhaust fan

ABSTRACT

A ventilating exhaust fan has a housing having a top, four sides, and an open bottom forming an air inlet. An exhaust outlet is located in one of the sides. A motor is housed within the housing and a fan is connected to the motor. The exhaust fan is mountable within an opening in a surface. The sides of the housing have a plurality of slots through which restraints can be inserted in order to connect the housing to the surface.

FIELD OF THE INVENTION

The present invention relates to the field of ventilation exhaust fansfor use in removing air from a bathroom or other area and venting it toan exterior location.

BACKGROUND OF THE INVENTION

Ventilation exhaust fans are used to vent air from a given room to anexterior location. They are typically used in bathrooms, where saturatedair from bath, shower and sink use can cause condensation and relatedproblems such as mold and mildew. By venting this saturated air, theventilation exhaust fan can limit the amount of condensation formed.These ventilation fans are also useful in removing stale air and odorsthat may be present in the bathroom.

The ventilation fan is typically mounted in the ceiling between thejoists, and is therefore limited in size by the space between the joistsand between the ceiling and the floor above it. An air inlet in thebottom of the ventilation fan draws air from the room below into thefan. An exhaust duct is connected to an exhaust outlet located on a sideof the ventilation fan. The duct directs air drawn into the air inlet ofthe ventilation fan from the bathroom (or other room where the fan isplaced) to a desired location, typically outside.

The bathroom fans of the prior art typically have a square casing havinga top, bottom and sides, with a maximum width corresponding to thedistance between the joists. The bottom is open, allowing the interiorcomponents to be fitted within the casing and forming the air inlet. Ablower housing is fitted within the casing interior and a centrifugalfan, sometimes referred to as a blower wheel, is fitted within theblower housing. A motor is secured within the casing, and connects tothe centrifugal fan, such that when it is activated, the motor acts torotate the centrifugal fan. A venturi plate having an air inlet is thenconnected to the casing. When rotated by the motor, the blower wheeldraws air in through the air inlet (aligned with the fan) and forces itradially outwards and in the direction of rotation of the wheel. Airbeing forced through the housing follows the rounded contour of the sidewall of the blower housing until it exits through the exhaust outlet(located in the side wall).

The ventilation exhaust fan is normally mounted into position duringconstruction of a house prior to installation of the ceiling drywall.Even at this time of relatively easy access, the fans can be difficultto install, as the fan must be positioned on the ceiling joist in such amanner that the drywall can be installed in proper abutment with thefan.

In order to overcome this problem, U.S. Pat. No. 6,802,770 teaches a fanhousing having two series of spaced view holes formed in the back wallso that the installer can see the ceiling joist during installation forproper positioning of the housing. In addition, the housing has a pairof bend down tabs along the back wall. The tabs are set in such aposition that when placed in abutment with the bottom of the ceilingjoist, the correct spacing will be provided for the drywall (of commonthickness). However, while the '770 patent makes it easier to install aventilation fan prior to putting the finishing drywall into place, it isof no use when installing a replacement fan in an already finishedceiling.

Replacing a fan, or installing a new fan through finished ceiling drywall is difficult to say the least. The installer is forced to workthrough a hole in the drywall that is sized to accommodate the fanhousing. Depending on the positioning of the hole in the drywall, theinstaller may have difficulty attaching the housing to the ceilingjoist. Working in a tight space makes this all the more difficult.

It is therefore an object of an embodiment of the present invention toprovide a ventilation exhaust fan that can be easily installed throughfinished drywall.

Other objects of the invention will be apparent from the descriptionthat follows.

SUMMARY OF THE INVENTION

According to the present invention there is provided a ventilationexhaust fan for mounting in an opening in a surface. The ventilationexhaust fan comprises a housing having a top, four sides and an openbottom. A motor and a fan are housed within the housing, the fan beingrotatable by the motor. An exhaust outlet is located in the housing. Aplurality of openings are located in the sides spaced above the bottom adistance corresponding to the thickness of the surface having theopening. A plurality of restraints are removably connectable to thehousing through the openings for mounting the housing to the surface.

According to the invention, the ventilating exhaust fan housingdescribed above is mountable in the opening in the surface by firstpositioning the housing in the opening so that the bottom is in abutmentwith one side of the surface and then inserting at least two of therestraints through the openings so that a portion of each of therestraints is in abutment with an opposite side of the surface.

Other aspects of the invention will be appreciated by reference to thedetailed description of the preferred embodiment and to the claims thatfollow.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the invention will become more apparent fromthe following description in which reference is made to the appendeddrawings and wherein:

FIG. 1 is an exploded perspective view of a preferred embodiment of aventilating exhaust fan;

FIG. 2 is a perspective view of the fan housing shown in FIG. 1;

FIG. 3 is a detailed view of a portion of a wall of the housing shown inFIG. 2 taken at the line 3-3;

FIG. 4 is a sectional view of a portion of a wall of the housing shownin FIG. 2 shown mounted to a portion of drywall using the preferredembodiment of a clip;

FIG. 5 is a sectional view of a portion of a wall of the housing shownin FIG. 2 shown mounted to a portion of drywall using an alternativeembodiment of a clip;

FIG. 6 is a sectional view of a portion of a wall of the housing shownin FIG. 2 shown mounted to a portion of drywall using a furtheralternative embodiment of a clip;

FIG. 7 is a perspective view of an alternative embodiment of aventilation exhaust fan housing;

FIG. 8 is a sectional view of a portion of a wall of the housing shownin FIG. 7 shown mounted to a portion of drywall using a furtheralternative embodiment of a clip; and

FIG. 9 is a perspective view of the clip shown in FIG. 8.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The preferred embodiment of a ventilation exhaust fan 10 is shown inFIG. 1. As shown in FIG. 1, the ventilation exhaust fan 10 has a housing12 having a top surface 14, four sides 16 and an open bottom 18. Theopen bottom 18 is bordered by flanges 28 extending outwards from each ofthe sides, substantially perpendicular thereto. An exhaust outlet 14 isdefined in one of the sides to which outlet fitting 2 is attachable.Outlet fitting 2 connects to an exhaust duct (not shown) for venting toan exterior location.

A blower housing 26 is mountable within the interior of housing 12. Amotor 22 and a fan 24 are fitted within the blower housing. A coverplate 8 attachable to the blower housing has an inlet opening throughwhich air is drawn in to the blower housing when the fan is inoperation. Motor 22 is connected to the fan, and when it is activated,the motor acts to rotate the fan, thereby acting to draw air through theair inlet opening into the blower housing where it is then forced outthe exhaust outlet 14 and outlet fitting 2 to the exhaust duct to bevented to an exterior location. A hinged door 4 allows air to flow outof the exhaust outlet 14 through the outlet fitting to the exhaust ductwhile preventing outside air from passing back through the blowerhousing 26 and into the room when the fan is shut off.

Electrical connection 7 is adapted for connection to a source ofelectrical power and is contained within power box 5.

The ventilating exhaust fan 10 is adapted for easy installation where aceiling drywall or other surface is already in place, either through anexisting opening in the surface or a new opening. According to apreferred embodiment of the invention, the housing has a plurality ofopenings 30 for connection to ceiling drywall by way of restraints, suchas clips 20 shown in FIG. 1 and FIG. 4. As best viewed in FIG. 3, theopening 30 is preferably in the form of an inverted “T” shaped slothaving a vertical slot 32 and a horizontal slot 34. The horizontal slots34 of openings 30 are positioned a suitable distance from the flanges 28to accommodate common ceiling surface thicknesses.

Clips 20 are formed of a solid material such as plastic or metal withsufficient strength and rigidity to support the ventilating exhaust fanon the ceiling drywall when installed in the ceiling. Preferably, theclips 20 are elongated planar members having a first portion 21 sized tofit through horizontal slot 34, a second portion 23 substantiallyperpendicular to first portion 21, and a third portion 25 substantiallyparallel to first portion 21. Preferably first portion 21 terminates inan upwardly angled portion 27. It is contemplated that a screw or otherconnector could be used to attach clip 20 in place on housing 12.

When installing the exhaust fan 10, after the ducting and electricalconnections are completed as known in the art, the housing 12 isinserted into an opening in a ceiling, connected to the alreadyinstalled components, and mounted in place. Once the housing is in placethe remaining components, including the motor and fan, are mounted intothe housing 12 and connected as necessary.

Using the easy-install system of the present invention, when the housing12 is inserted into an opening in a surface for mounting, it ispositioned so that the bottom, in this case flanges 28, are in abutmentwith the ceiling drywall 36 as shown in FIG. 4. Clips 20 are insertedthrough openings 30 so that first portion 21 sits above and in abutmentwith drywall 36, second portion 23 is in abutment with that portion ofwall 16 below horizontal slot 34, and third portion 25 is in abutmentwith the underside of flange 28. Upwardly angled portion 27 makes iteasier to clear the edge of drywall 36 when inserting the clip 20through horizontal slot 34. The clips 20 transfer the weight of theexhaust fan 10 to the drywall 36, thereby supporting it in the ceiling.Should a user wish to remove the exhaust fan housing, they need simplyuse a screwdriver or like instrument to pry out the clips. The clipscould also be used with a housing with sides terminating in an openbottom with no flanges, as third portion 25 is in abutment with thebottom side of surface 36, with a portion of surface 36 being sandwichedbetween first portion 21 and third portion 25.

It is contemplated that different models of ventilating exhaust fan canbe adapted for different thicknesses of drywall, by simply varying thedistance of the horizontal slot 34 from the flange 28. Alternatively,different clips can be used for different sized drywall as shown in FIG.5. In FIG. 5, the clip has a first portion 31 terminating in an upwardlyangled portion 27, a second portion 33 and a third portion 35. A steppedportion 39 raises the level of the first portion 31 above the level ofhorizontal slot 34 so that the clip sits flush when the clip is forcedall the way into place.

A further alternative restraint is shown in FIG. 6. Clip 50 has avertical portion 52 and a horizontal portion 54 substantiallyperpendicular thereto. Horizontal portion 54 terminates in an upwardlyangled portion 57. When installing the housing in an opening in theceiling, clip 50 is inserted through opening 30 such that horizontalportion 54 is fitted through horizontal slot 34 above drywall 36.Vertical portion 52 is connected to vertical slot 32 by way of a screw40 or like connector. Having a vertical slot allows for varied placementof the screw 40 depending on the alignment of the vertical portion 52.

A further alternative embodiment is shown in FIGS. 7 through 9, wherethe plurality of openings 65 in the side walls 66 of the housing 60 aresmall circular openings through which restraints 64 may be inserted tosupport the housing 60 on the drywall 36. The restraint 64 is preferablya solid, pre-formed wire or plastic cylindrical element dimensioned tofit within opening 65. Preferably restraints 64 are substantiallyu-shaped with a first portion 61, second portion 63 and third portion65.

It is also contemplated that other shapes and sizes of openings andrestraints could be used, provided that they involve the insertion of aplurality of restraints through a plurality of openings in the housingto support the housing and ventilating exhaust fan on the ceilingdrywall within which it is mounted. Similarly, multiple openings toaccommodate different sized drywall could be included on each side ofthe housing. For example, each side could have two openings per side toaccommodate ½ inch drywall and another two opening per side toaccommodate ⅝ inch drywall, two of the most common sizes. Other sizescould also be provided for.

Preferably the housing 12 is also equipped with the standard parts andfittings for mounting within a ceiling as known in the art. For example,the housing could be connected directly to a joist by way of screw orlike connection passing through a defined opening in the housing asknown in the art. Referring to FIG. 1, a screw can be inserted throughopening 19 to fasten the housing 12 to a ceiling joist.

The easy-install housing of the present invention can be installed usingthe following method. The housing is inserted into an opening in asurface such as a ceiling until the bottom (flanges 28) is in abutmentwith one side of the surface having the opening within which it is beingmounted. Any connections required to be made for the functionality ofthe exhaust fan are completed. Holding the housing in position, at leasttwo restraints are inserted through openings in the housing in order toconnect the housing to the ceiling drywall. Any further connections arethen made in order to complete the functionality of the exhaust fan,including connecting a decorative fan grill (not shown) for safety andaesthetics.

While the exhaust fan has been described being mounted in a surface in aceiling, it is also contemplated that it could be mounted in a wall orother surface, the housing being adaptable to such variations by way ofit being mounted to the surface itself by way of the restraints andcorresponding openings in the housing. Similarly, while the surfacebeing described has been referred to as drywall, it could also bemounted in an opening in any other surface, such as wood or particleboard, having a suitable thickness.

It will be appreciated by those skilled in the art that the preferredand alternative embodiments have been described in some detail but thatcertain modifications may be practiced without departing from theprinciples of the invention.

1. A ventilation exhaust fan for mounting in an opening in a surface,said ventilating exhaust fan comprising: a housing having a top, foursides and an open bottom; a motor and a fan housed within said housing,said fan being rotatable by said motor; an exhaust outlet located insaid housing; a plurality of openings in said sides spaced above saidbottom a distance corresponding to a ceiling surface thickness; and aplurality of restraints, said restraints being removably connectable tosaid housing through said openings for mounting said housing to saidsurface.
 2. The ventilation exhaust fan of claim 1 wherein saidplurality of openings are in the shape of an inverted “T”.
 3. Theventilation exhaust fan of claim 2 wherein said restraints comprisingpre-formed, flat, elongated “U”-shaped members having a first portioninsertable through any one of said plurality of openings and a secondportion perpendicular thereto.
 4. The ventilation exhaust fan of claim 2wherein said restraints comprising pre-formed, flat, elongated “L”shaped members having a first portion insertable through any one of saidplurality of openings and a second portion perpendicular thereto.
 5. Theventilation exhaust fan of claim 2 wherein when said first portion isinserted through one of said plurality of openings, said second portionis releasably connected to a portion of said one of said plurality ofopenings.
 6. The ventilation exhaust fan of claim 1 further comprising aflange extending perpendicularly outwards from each wall at said bottom,said restraints coordinating with said flanges such that when mounted tosaid surface, a portion of said surface is sandwiched between a portionof said restraint and a portion of said flange.
 7. A housing formounting in an opening in a surface and housing components of aventilation exhaust fan, including a motor and fan, wherein said housingcomprises: a top, four sides and a bottom, an inlet opening beinglocated in said bottom, and an exhaust outlet being located in one ofsaid top and four sides; a plurality of openings located in said sidesspaced above said bottom a distance corresponding to a ceiling surfacethickness; and a plurality of restraints, said restraints beingremovably connectable to said housing through said openings for mountingsaid housing to said surface.
 8. A method of mounting the ventilationexhaust fan housing of claim 7 in an opening in a surface comprising:positioning the housing in said opening such that said bottom is inabutment with one side of said surface; inserting at least two of saidplurality of restraints through at least two of said plurality ofopenings such that a portion of each of said restraints is in abutmentwith a second opposite side of said surface.